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Summary of Contents for ITW Gema OptiFlex L
- Page 1 Operating instructions and spare parts list Manual coating equipment OptiFlex...
- Page 2 To the best of our knowledge and belief, the information contained in this publication was correct and valid on the date of issue. ITW Gema AG makes no representations or warranties with respect to the contents or use of this publication, and reserves the right to revise this publication and make changes to its content without prior notice.
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Page 3: Table Of Contents
Product specific security measures ..............10 About this manual General information ....................11 Function description Field of application ....................13 Typical characteristics...................13 OptiFlex L manual coating equipment ..............14 Structure....................14 OptiStar control unit .................14 OptiSelect manual powder gun..............14 OptiFlow injector ..................14 Fluidized powder hopper................14 Scope of delivery ....................16... - Page 4 OptiFlex L manual coating equipment - spare part list......... 34 OptiFlex L manual coating equipment - spare parts ..........35 OptiFlex L manual coating equipment - spare parts list ........36 OptiFlex L manual coating equipment - spare parts ..........37 OptiFlex L manual coating equipment - powder hopper ........
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Page 5: General Safety Regulations
V 12/06 General safety regulations This chapter sets out the fundamental safety regulations that must be fol- lowed by the user and third parties using the OptiFlex L manual coating equipment. These safety regulations must be read and understood before the OptiFlex L manual coating equipment is used. -
Page 6: Technical Safety Regulations For Stationary Electrostatic Powder Spraying Equipment
4. Start-up (i.e. the execution of a particular operation) is forbidden until it has been established that the OptiFlex L manual coating equipment has been set up and wired according to the guidelines for machinery (98/37 EG). EN 60204-1 (machine safety) must also be observed. -
Page 7: Safety Conscious Working
Individual safety regulations for the operating firm and/or operating personnel 1. Any operating method which will negatively influence the techni- cal safety of the powder spraying equipment is to be avoided. General safety regulations • 5 OptiFlex L manual coating equipment... -
Page 8: Notes On Special Types Of Hazard
Charging of objects must be avoided - see "Earthing". Grounding/Earthing All electricity conducting parts and machinery found in the workplace (ac- cording to DIN VDE 0745, part 102) must be earthed 1.5 meters either 6 • General safety regulations OptiFlex L manual coating equipment... -
Page 9: Safety Requirements For Electrostatic Powder Coating
Repairs must only be carried out by specialists or in ITW-Gema work- shops. Unauthorized conversions and modifications may lead to injury or damage to machinery. The ITW Gema AG guarantee would no longer be valid. Safety requirements for electrostatic powder coating 1. -
Page 10: A Summary Of The Rules And Regulations
General regulations BGV A2 Electrical equipment and material BGI 764 Electrostatic coating BGR 132 Guidelines for the avoidance of the dangers of ignition due to electrostatic charging (Guideline “Static Electric- ity”) 8 • General safety regulations OptiFlex L manual coating equipment... - Page 11 Beuth Verlag GmbH, Burgrafenstrasse 4, 1000 Berlin 30 General secretariat, Rue Bréderode 2, B-1000 Bruxelles, or the appro- priate national committee VDE Verlag GmbH, Bismarckstrasse 33, 1000 Berlin 12 General safety regulations • 9 OptiFlex L manual coating equipment...
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Page 12: Product Specific Security Measures
(input and exhaust air) It must be observed, that all components are grounded ac- cording to the local regulations, before start-up 10 • General safety regulations OptiFlex L manual coating equipment... -
Page 13: About This Manual
General information This operating manual contains all the important information which you require for the working with the OptiFlex L manual coating equipment. It will safely guide you through the start-up process and give you refer- ences and tips for the optimal use of your new powder coating system. -
Page 15: Function Description
V 12/06 Function description Field of application The OptiFlex L manual coating equipment (with fluidized powder hopper) is designed exclusively for electrostatic coating with organic powders. Any other use is considered as non-conform. The manufacturer is not re- sponsible for any damage resulting from this, the risk for this is assumed... -
Page 16: Optiflex L Manual Coating Equipment
V 12/06 OptiFlex L manual coating equipment Structure OptiFlex L manual coating equipment - structure OptiStar control unit Clamping element OptiSelect manual powder gun Pneumatic connection Powder container Filter unit Injector Tube Rack Base OptiStar control unit All information about the OptiStar control unit will be found in the corre-... - Page 17 The powder is fluidized by air forced through a porous plastic plate from below. The powder acquires, thereby, fluid-like characteristics. The conveying air, supplementary air, and rinsing air are set on the con- trol unit. Fluidized powder hopper - function Function description • 15 OptiFlex L manual coating equipment...
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Page 18: Scope Of Delivery
(see therefore the OptiSelect manual powder gun user man- ual) Pneumatic hoses for conveying air (red), supplementary air (black) and fluidizing air (black) 16 • Function description OptiFlex L manual coating equipment... -
Page 19: Technical Data
V 12/06 Technical data OptiFlex L manual coating equipment Electrical data OptiFlex L Mains input voltage 100-240 VAC Operating frequency 50/60 Hz Input power 40 VA Nominal output voltage (to the gun) max. 12 V Nominal output current (to the gun) max. -
Page 20: Connectable Guns
* The gun type must be set on the control unit (see therefore the corre- sponding user manual)! Attention: The OptiFlex L manual coating equipment can only be used with the specified gun types! Dimensions OptiFlex L... -
Page 21: Start-Up And Operation
(this hose is electrically conductive) 9. Connect the mains cable to the 2.1 Power IN plug and screw it on Note: Close the 2.2 Aux output with the provided dust protection cap! Start-up and operation • 19 OptiFlex L manual coating equipment... -
Page 22: Preparation For Start-Up
4. Adjust the fluidization on the control unit (see also the OptiStar CG07control unit operating instructions, chapter "Setting the flu- idizing") Switch on the booth The coating booth is switched on according to the corresponding user manual. 20 • Start-up and operation OptiFlex L manual coating equipment... -
Page 23: Start-Up
The displays illuminate and the control unit is ready for operation Note: The further start-up procedure for the OptiFlex B manual coating equipment is explicitly described in the OptiStar CG07control unit operating instructions (chapter "Initial start-up" and "Daily start- up")! Start-up and operation • 21 OptiFlex L manual coating equipment... -
Page 25: Color Change
OptiSelect manual powder gun) 4. Clean the injector (see therefore the user manual of the OptiFlow injector) 5. Prepare the manual coating equipment with new powder for start-up Color change • 23 OptiFlex L manual coating equipment... -
Page 27: Maintenance And Cleaning
2. Point the gun into the booth 3. Blow through the hose manually with a compressed air gun 4. Fit the powder hose again to the hose connection on the injector Maintenance and cleaning • 25 OptiFlex L manual coating equipment... -
Page 28: Cleaning
6. Blow through the gun with compressed air again 7. Clean the powder hose 8. Reassemble the gun and connect it Note: See therefore the user manual of the OptiSelect manual powder gun! 26 • Maintenance and cleaning OptiFlex L manual coating equipment... -
Page 29: Maintenance And Cleaning Of The Filter Unit
V 12/06 Maintenance and cleaning of the filter unit The filter unit on the OptiFlex L manual coating equipment measures and cleans the compressed air. Here, the main compressed air connection of the equipment is located. Replacing the filter element Procedure: 1. -
Page 31: Troubleshooting
(application key) though the gun is trig- High voltage cascade Send in the gun for re- gered and sprays defective pair powder Objects are not properly Check the grounding grounded Troubleshooting • 29 OptiFlex L manual coating equipment... - Page 32 Insert the insert sleeve Fluidizing not running (see above) No conveying air: Throttle motor defective Replace the throttle mo- Solenoid valve defective Replace the solenoid valve Front plate defective Send in for repair 30 • Troubleshooting OptiFlex L manual coating equipment...
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Page 33: Schematic Diagrams
V 12/06 Schematic diagrams Pneumatic diagram - OptiFlex L Supplementary air Zusatzluft OptiStar CG07 Conveying air Foerderluft Suction Absaugung Auf 5,5 bar einstel- Adjust to 5,5 bar by Auf 5.5 bar einstellen bei len bei Luftver- 6 Nm³/h air con-... -
Page 35: Spare Parts List
WARNING! Only original ITW-Gema spare parts should be used, because the explosion protection will also be preserved that way. The use of spare parts from other manufacturers will invalidate the ITW Gema guarantee conditions! Spare parts list • 33 OptiFlex L manual coating equipment... -
Page 36: Optiflex L Manual Coating Equipment - Spare Part List
V 12/06 OptiFlex L manual coating equipment - spare part list Base complete 385 190 Filter unit - complete (see corresponding spare parts list) CG07 gun control unit - complete (see corresponding operating manual) Powder hopper - complete (see corresponding spare parts list) -
Page 37: Optiflex L Manual Coating Equipment - Spare Parts
V 12/06 OptiFlex L manual coating equipment - spare parts OptiFlex L manual coating equipment - spare parts Spare parts list • 35 OptiFlex L manual coating equipment... -
Page 38: Optiflex L Manual Coating Equipment - Spare Parts List
V 12/06 OptiFlex L manual coating equipment - spare parts list Gun retainer 1001 140 Mains cable - L=5m, 12 G (Switzerland) 382 493 Mains cable - L=5m, VII G Schuko (Europe, Russia etc.) 382 485 Mains cable - L=5m, 498 G (USA, Japan etc.) 382 507 Mains cable - L=5m, BS89/5 (GB, Africa etc.) -
Page 39: Optiflex L Manual Coating Equipment - Spare Parts
V 12/06 OptiFlex L manual coating equipment - spare parts OptiFlex L manual coating equipment - spare parts Spare parts list • 37 OptiFlex L manual coating equipment... -
Page 40: Optiflex L Manual Coating Equipment - Powder Hopper
V 12/06 OptiFlex L manual coating equipment - powder hopper Powder hopper - complete (incl. pos. 1-21) 379 441 379 484 Hopper body Base plate 379 492 Spacing ring 382 191 310 468 Fluidizing bed Cover 379 450 371 890 Suction tube holder - complete (incl. -
Page 41: Optiflex L Manual Coating Equipment - Powder Hopper
V 12/06 OptiFlex L manual coating equipment - powder hopper OptiFlex L manual coating equipment - powder hopper Spare parts list • 39 OptiFlex L manual coating equipment... -
Page 42: Optiflex L - Filter Unit
V 12/06 OptiFlex L - filter unit Filter unit - complete, without pos. 13 1001 147 Filter separator body - F14MD 1001 759 T-piece - 1/4"i-1/4"a-1/4"i 262 064 Elbow joint - 1/4"-Ø 8/3x1 mm 1002 614 Fixture plate 1001 758... - Page 43 V 12/06 Spare parts list • 41 OptiFlex L manual coating equipment...
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